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Automation Direct Stellar SR55 Series User Manual

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Stellar® SR55 Soft Starter User Manual
SR55_UMW
First Edition, Revision F

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Summary of Contents for Automation Direct Stellar SR55 Series

  • Page 1 ® Stellar® SR55 Soft Starter User Manual SR55_UMW First Edition, Revision F...
  • Page 2 BLANK PAGE ® Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...

  • Page 3: Warnings And Trademarks

    arnings and rademarks ~ WARNING ~ Thank you for purchasing automation equipment from Automationdirect.com®, doing business as AutomationDirect. We want your new automation equipment to operate safely. Anyone who installs or uses this equipment should read this publication (and any other relevant publications) before installing or operating the equipment.

  • Page 4: Avertissement

    ~ AVeRTIssemeNT ~ Nous vous remercions d’avoir acheté l’équipement d’automatisation de Automationdirect.com®, en faisant des affaires comme AutomationDirect. Nous tenons à ce que votre nouvel équipement d’automatisation fonctionne en toute sécurité. Toute personne qui installe ou utilise cet équipement doit lire la présente publication (et toutes les autres publications pertinentes) avant de l’installer ou de l’utiliser.

  • Page 5: Warnings

    ARNINGs he owner insTaller and user are responsible for The correcT insTallaTion and use of The ® sr55, sr55, Tellar for ensuring ThaT only qualified personnel insTall The and for ensuring ThaT The operaTion and mainTenance of The uniT complies wiTh The relevanT odes of racTice egulaTions...
  • Page 6 BLANK PAGE ® Page W–4 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 7 Stellar® SR55 Soft Starter User Manual anual evision isTory Please include this Manual Number and the Manual Issue, both shown below, when communicating with AutomationDirect Technical Support regarding this publication. Manual Number: SR55_UMW Manual Issue: First Edition, Revision F Issue Date: 09/18/2019 Publication History Issue...
  • Page 8 BLANK PAGE ® Page H–2 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...

  • Page 9: Table Of Contents

    SR55 U anUal able of onTenTS onTenTS onTenTS onTenTS Contents of Stellar SR55 Soft Starters User Manual Stellar SR55 Soft Starters User Manual � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � CF–1 Warnings and Trademarks �...
  • Page 10 Table of Contents Chapter 3: Configuration and Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3–1 “Heartbeat” LED � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3–2 Configuration Overview�...
  • Page 11 Table of Contents Chapter 5: Communications� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5–1 SR55 Communications Overview�...
  • Page 12 Table of Contents Appendix B: Soft Starter Application Considerations � � � � � � � � � � � � � � � � � � � � � � � B–1 B�1 – Motor Suitability and Associated Considerations � � � � � � � � � � � � � � � � � � � � � � � B–2 B�1�1 –...
  • Page 13 Table of Contents Appendix C: Electromagnetic Compatibility � � � � � � � � � � � � � � � � � � � � � � � � � � � � C–1 C�0 – Electromagnetic Compatibility (EMC) � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � C–2 C�1 –...
  • Page 14 Table of Contents BLANK PAGE ® TOC–6 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 15 hapter hapter hapter echanical nstallation Table of Contents Chapter 1: Mechanical Installation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 1–1 User Manual Overview �...

  • Page 16: Chapter 1: Mechanical Installation

    Chapter 1: Mechanical Installation ANuAl VeRVIeW Overview of this Publication The SR55 Soft Starter User Manual describes the installation, configuration, and methods of operation of the SR55 Soft Starter. Who Should Read This Manual This manual contains important information for those who will install, maintain, and/or operate any of the SR55 Soft Starters.

  • Page 17: Mechanical Installation

    Chapter 1: Mechanical Installation echANIcAl NsTAllATIoN Mounting Mount the soft starter to a flat, vertical surface using the mounting holes (or slots) on its base plate. The dimension drawings, shown in the “Dimensions” subsection of this chapter, give mounting hole positions and overall dimensions for each SR55 model. Ensure that: •...

  • Page 18: Mechanical Specifications

    Chapter 1: Mechanical Installation Mechanical Specifications MECHANICAL SPECIFICATIONS – SR55 Series Full-Featured Soft Starters SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 Model -017 -021 -027 -034 -040 -052 -065 -077 -096 Frame Size Heat Output (W) 25�5 31�5 40�5 51�0 60�0...
  • Page 19 Chapter 1: Mechanical Installation Dimensions ( in [mm] ) (continued) Frame Size 2: SR55-124 – SR55-180 Minimum Clearance Distance Mount soft starter within 30° of vertical 3�9 in [100mm] Bottom Left 1�6 in [40mm] Right Front 1in [25mm] NOTE: The addition of optional finger guards to size 1 and size 2 SR55 soft starters adds approximately...
  • Page 20 Chapter 1: Mechanical Installation BLANK PAGE ® Page 1–6 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 21 haptEr haptEr haptEr lEctrical nstallation able of onTenTs Chapter 2: Electrical Installation                                   2–1 Safety Warning                                           2–2 Agency Approvals                                          2–2 Technical Information and Standards                               2–2...
  • Page 22 Chapter 2: Electrical Installation AfeTy ARNING sr55 sofT sTarTers conTain dangerous volTages when connecTed To The elecTrical power supply nly qualified personnel who have been compleTely Trained and auThorized should carry ouT insTallaTion operaTion and mainTenance of This equipmenT efer To and carefully “w ”...
  • Page 23 Chapter 2: Electrical Installation lecTRIcAl pecIfIcATIoNs ELECTRICAL SPECIFICATIONS – SR55 Series Full-Featured Soft Starters SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 Model -017 -021 -027 -034 -040 -052 -065 -077 -096 Frame Size Rated Current [UL FLC] (A) Rated Operational Voltage 200VAC to 480VAC Motor Rating @ 200V (hp)
  • Page 24 Chapter 2: Electrical Installation IRcuIT RoTecTIoN horT irCuiT roTeCTion External Short-Circuit Protection Required for SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 SR55 Model Number -017 -021 -027 -034 -040 -052 -065 -077 -096 UL FLC Rated Operational Current IEC I Mersen 6,9 URD 30xx Bussmann 170M30xx...
  • Page 25 Chapter 2: Electrical Installation oTor overload roTeCTion The SR55 soft starter provides full motor overload protection, which can be configured through the touch screen. Overload trip settings are determined by the Motor Current setting and the Trip Class setting. Trip class choices are Class 10, Class 20, and Class 30. The SR55 soft starters are protected using full I T motor overload with memory.
  • Page 26 Chapter 2: Electrical Installation lecTRIcAl oNNecTIoNs Pro- Pro- Required Descrip- Descrip- Required gram- Default Control Terminals Default gram- Rating tion tion Rating mable mable group group 1 – – – – 1 input relay – – – D1COM common common 24VDC or 230VAC 1A opto-...
  • Page 27 Chapter 2: Electrical Installation lecTRIcAl IRING oWer irCuiT iring In Line In Delta NOTE: Circuit breaker isolation alone is not allowed for In-Delta operation. K1 (Main contactor) K1 – Main contactor controlled by the Run and protection switch gear K1 – Main contactor or relay on the SR55 MUST (provided by the customer) circuit breaker isolation...
  • Page 28 Chapter 2: Electrical Installation onTrol irCuiT iring 1) T d1com, d1-1i, d1-2i, d2com, d2-1i he programmed digiTal inpuT seTTings for musT correspond To The volTage applied To These Terminals To avoid risk of damage To The equipmenT 2) T 230vac n, l 24vdc he conTrol supply can be...
  • Page 29 Chapter 2: Electrical Installation eversing iring iagram Reversing Wiring Diagram Control supply 110/230VAC or 24VDC Protection switch Emergency Stop depending on application gear (provided by the customer) Enable Stop Reset Forward Reverse SR55 3/L2 5/L3 SR55 L or 24VDC D1-1I D2-1I N or 0VDC D1COM...
  • Page 30 Chapter 2: Electrical Installation BLANK PAGE ® Page 2–10 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...

  • Page 31: Chapter 3: Configuration And Parameters

    haPter haPter haPter onfiguration and arameters able of onTenTs Chapter 3: Configuration and Parameters � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3–1 “Heartbeat”...

  • Page 32: Heartbeat" Led

    Chapter 3: Configuration and Parameters “h ” led eARTbeAT The Stellar logo LED on the SR55 front panel will blink once every 10 seconds to let the user know that all microprocessors in the soft starter are operating properly. oNfIGuRATIoN VeRVIeW Configuring the SR55 soft starters for use is as simple as setting the parameters to match your motor, application, power source, etc.

  • Page 33: Touchscreen Pictorial Example - Auto Setup

    Chapter 3: Configuration and Parameters – a ouChsCreen iCTorial xample eTup Setup Wizard Please note: This “Setup Wizard” screen appears only once; on the initial power-up of the SR55 soft starter. For subsequent start-ups, screen 1a will be the Auto first screen displayed.

  • Page 34: Auto Setup Procedure - Parameter Settings

    Chapter 3: Configuration and Parameters – p eTup RoceduRe ARAmeTeR eTTINGs Choose “Auto” setup from the “Setup Wizard” or from the “Home” menu, and set the following parameter groups: 1) Application 2) Motor Current Rating 3) Control Method 4) Digital Input Voltage The SR55 will automatically set the rest of the parameters as shown in the following table: Auto Setup Parameter Settings Application...
  • Page 35 Chapter 3: Configuration and Parameters Auto Setup Parameter Settings (continued from previous page) Application – Unit – FLC s – FLC s Pump - Submersible 3�5 Rotodynamic Pump - Positive displacement 3�5 Reciprocating Pump - Positive displacement 3�5 Rotary Pump Jack 3�5 Rolling mill 3�5...

  • Page 36: Parameter Summary

    Chapter 3: Configuration and Parameters ARAmeTeR ummARy ummary of arameTers onfigurable hrough ouChsCreen These parameters are configurable through network communications. Summary – Parameters Not Configurable Through Touchscreen Read / Modbus Default User Group Parameter Units Range Write Setting Setting Address Hex P0�0 –...

  • Page 37: Summary Of Parameters For Individual Parameter Setup

    Chapter 3: Configuration and Parameters ummary of arameTers for ndividual arameTer eTup grouped by TouChsCreen navigaTion “a ” m – s arameTers from dvanCed aTegory ummary Summary – Parameters for Touchscreen Setup – “Advanced” Category Modbus Read / Default User Group Parameter Units...
  • Page 38 Chapter 3: Configuration and Parameters Summary – Parameters for Touchscreen Setup – “Advanced” Category (continued) Modbus Read / Default User – Group Parameter Units Range Write Setting Setting Address Hex P5�0 – Motor Current 10% to 100% of SR55 rated A 25728 6480 100%...
  • Page 39 Chapter 3: Configuration and Parameters Summary – Parameters for Touchscreen Setup – “Advanced” Category (continued) Modbus Read / Default User – Group Parameter Units Range Write Setting Setting Address Hex P9�0 – Firing Mode toggle In-Delta / In-Line 0080 In-Line P9�1 –...
  • Page 40 Chapter 3: Configuration and Parameters Parameter Summary for Touchscreen Setup – “I/O” Category (continued) Modbus Read / Default User – Group Parameter Units Range Write Setting Setting P13�0 – Analog Output Type toggle 0–10V / 4–20mA 8960 2300 0–10V (P13) Analog Outputs Current Measured...
  • Page 41 Chapter 3: Configuration and Parameters “l ” m – s arameTers from aTegory ummary Summary – Parameters for Touchscreen Setup – “Log” Category Modbus Read / Default User Group Parameter Units Range Write Setting Setting Address Hex P16�0 – (Event Time) Last Peak Start Current / Last Read 38464...
  • Page 42 Chapter 3: Configuration and Parameters Summary – Parameters for Touchscreen Setup – “Log” Category (continued) Modbus Read / Default User – Group Parameter Units Range Write Setting Setting Address Hex P19�0 – Last Peak Stop Current 0 to 10,000 Read 39040 9880 –...
  • Page 43 Chapter 3: Configuration and Parameters “d ” m – s arameTers from eviCe aTegory ummary Summary – Parameters for Touchscreen Setup – “Device” Category Modbus Read / Default User Group Parameter Units Range Write Setting Setting Address Hex P25�0 – Update Firmware –...
  • Page 44 Chapter 3: Configuration and Parameters lock RANsfeR ARAmeTeRs Parameters P0.20~P0.35 and P0.40~P0.55 NOTE: These Block Transfer parameters can only be accessed through Modbus; not through the Touchscreen Menu. Block Transfer allows parameters from many different Parameter Groups to be consolidated into one Modbus communication message.

  • Page 45: Parameter Details

    Chapter 3: Configuration and Parameters ARAmeTeR eTAIls This section describes the individual parameters and the functions that they perform. SR55 parameters are defined as holding type registers. arameTers onfigurable hrough ouChsCreen These parameters are configurable only through network communications. arameTers ssoCiaTed igiTal npuTs...
  • Page 46 Chapter 3: Configuration and Parameters – n – a arameTer eTails onfigurable hrough ouChsCreen ssoCiaTed igiTal npuTs ConTinued P0.3 – External Trip (Digital Input Control Command Function) Hold. Reg. Type: Description: Read/Write Control command for Digital Input: External Trip. • Ensure start signal is low before reset. •...
  • Page 47 Chapter 3: Configuration and Parameters – n – a arameTer eTails onfigurable hrough ouChsCreen ssoCiaTed igiTal uTpuTs ConTinued P0.6 – Error Hold. Reg. Type: Description: Read Only STATUS INDICATION : Error. The fault must be cleared before a reset. • To map to Digital Output, refer to P11.0, P11.2, P11.4, P11.6. Range: Modbus Decimal Value: Default (decimal):...
  • Page 48 Chapter 3: Configuration and Parameters – n – a arameTer eTails onfigurable hrough ouChsCreen ssoCiaTed igiTal uTpuTs ConTinued P0.10 – iERS Active Hold. Reg. Type: Description: Read Only STATUS INDICATION : iERS Active • To map to Digital Output, refer to P11.0, P11.2, P11.4, P11.6. Range: Modbus Decimal Value: Default (decimal):...
  • Page 49 Chapter 3: Configuration and Parameters arameTers ssoCiaTed loCk ransfers Hold. Reg. Type: P0.20~P0.35 – Block Transfer Address Pointers Description: Read/Write Address pointers for data block transfer. • For details, please refer to “Block Transfer Parameters” on page 3–14. Range: Modbus Decimal Value: Default (decimal): •...

  • Page 50: Parameter Details

    Chapter 3: Configuration and Parameters arameTer eTails ConTinued arameTers in equenCe and rouped by ouChsCreen avigaTion SR55 parameters are defined as holding type registers. “a ” m eTup enu of arameTers P0.11 – Application Holding Register Type: Description: Read/Write • The SR55 has numerous built-in preset applications. Select the application best suited to your load.

  • Page 51: Auto Setup" Menu Of Parameters

    Chapter 3: Configuration and Parameters – “a ” m arameTer eTails eTup enu of arameTers ConTinued P7.0 – Control Method Holding Register Type: Description: Read/Write • Local Touch Screen : Control using the buttons on the keypad. • User Programmable : Control using the terminals, function defined in “I/O” menu. •...

  • Page 52: Advanced" Menu Of Parameters

    Chapter 3: Configuration and Parameters “a ” m dvanCed enu of arameTers P1.0 – Save Parameters Hold. Reg. Type: Description: Read/Write Saves all Read/Write parameters to non-volatile memory. Note: This does not save the parameters to an external USB drive. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 53 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P2.3 – Automatic Stop Hold. Reg. Type: Description: Read/Write Automatically controls the soft stop to suit the application. This feature is particularly useful with pumping applications Range: Modbus Decimal Value: Default (decimal): •...
  • Page 54 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P2.7 – Auto Smooth Stop Hold. Reg. Type: Description: Read/Write Automatically controls the soft stop to eliminate oscillations that can occur towards the end of the ramp.
  • Page 55 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P2.10 – Automatic End Start (3) Hold. Reg. Type: Description: Read/Write Automatically controls the time taken for the motor to start. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 56 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P3.1 – Start Pedestal Hold. Reg. Type: Description: Read/Write • Percentage of the supply voltage applied to motor at the beginning of the soft start. •...
  • Page 57 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P3.5 – Kick Start Hold. Reg. Type: Description: Read/Write Applies a short duration torque pulse to dislodge ‘sticky’ loads. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 58 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued “s ” p dvanCed eTTings arameTers P4.0 – Stop Time Type: Description: Read/Write Normally set between 15 and 60 seconds. • Actual time to get to ‘Stop Pedestal’ depends on the “”Stop Current Limit Level.” •...
  • Page 59 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P4.3 – Stop Current Limit Level Type: Description: Read/Write The current in amps at which the soft stop ramp is not allowed to go above. •...
  • Page 60 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P5.1 – Trip Class Hold. Reg. Type: Description: Read/Write • The trip class is a numeric value that correlates the trip time with overload level. Select “Trip Class”...
  • Page 61 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P5.5 – Shearpin Trip Hold. Reg. Type: Description: Read/Write The shearpin is an electronic equivalent of a mechanical shearpin. • This feature is not active during soft start and soft stop. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 62 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P5.9 – Overload Level Type: Description: Read/Write Determines the level in Amps at which the overload will start. • Normally set to 115% of the set motor current (i-motor). •...
  • Page 63 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P6.2 – iERS Rate Type: Description: Read/Write Determines the rate at which the load is regulated during the energy saving mode. • Increase if the applications shows signs of instability. •...
  • Page 64 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P6.5 – Fixed Voltage Hold. Reg. Type: Description: Read/Write Selects the source for the voltage value used in the power calculations. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 65 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued “T ” p dvanCed eTTings arameTers P8.0 – Trip Sensitivity Type: Description: Read/Write Adjusts the reaction time to fault trips. • Increase “Trip Sensitivity” to slow the response to fault trips. •...
  • Page 66 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P8.3 – Overload Trip Hold. Reg. Type: Description: Read/Write The overload is an electronic equivalent to a thermal overload. (See Overload parameter address 33408 for more information about Overload.) Range: Modbus Decimal Value: Default (decimal): •...
  • Page 67 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P8.6 – Stop Current Limit Trip Hold. Reg. Type: Description: Read/Write Selects between trip or continue if the stop current limit has been active for too long. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 68 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P8.10 – Remote Start Trip Hold. Reg. Type: Description: Read/Write For safety reasons the SR55 will trip during some operations if the “Start/Stop” signal is active. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 69 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P8.14 – Shut Down (1) * Hold. Reg. Type: Description: Read/Write This features controls the soft stop to improve stability. • Shut Down Trip 1 is an overlap trip. If firing patterns get overlapped at the beginning of stop ramp this trip will occur.
  • Page 70 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P8.17 – Motor Side Phase Loss Hold. Reg. Type: Description: Read/Write Detects if there is a disconnection between the SR55 output and the motor. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 71 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued P8.21 – Main Board Trip Hold. Reg. Type: Description: Read/Write Detects if an unexpected event has occurred during the Main Board operation. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 72 Chapter 3: Configuration and Parameters “f ” p dvanCed iring arameTer P9.0 – Firing Mode Hold. Reg. Type: Description: Read/Write Set to correspond with SR55 connection to the Motor. Refer to connection diagrams in the Quick Start Guide, or in the “Electrical Installation” Chapter 2 of this user manual. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 73 Chapter 3: Configuration and Parameters – “a ” m arameTer eTails dvanCed enu of arameTers ConTinued Hold. Reg. Type: P9.3 – Hand-Auto Control Description: Read/Write A Hand-Auto selection switch can be connected to Digital Input D1-2I to change the ‘Control Method.’...
  • Page 74 Chapter 3: Configuration and Parameters arameTer eTails ConTinued “i/o” m enu of arameTers i/o “d ” p igiTal npuTs arameTers P10.0 – Digital Input Voltage Hold. Reg. Type: Description: Read/Write The digital inputs D1-1I, D1-2I, D2-1I are designed to work with a range of control supplies. •...
  • Page 75 Chapter 3: Configuration and Parameters – “i/o” m arameTer eTails enu of arameTers ConTinued P10.2 – Digital Input 1 (D1-1I): High Input = 1 Sets Value Hold. Reg. Type: Description: Read/Write Allows the polarity of the input to be reversed. Range: Modbus Decimal Value: Default (decimal): •...

  • Page 76: I/O" Menu Of Parameters

    Chapter 3: Configuration and Parameters – “i/o” m arameTer eTails enu of arameTers ConTinued P10.6 – Digital Input 3 (D2-1I): High Input = 1 Sets Value Hold. Reg. Type: Description: Read/Write Allows the polarity of the input to be reversed. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 77 Chapter 3: Configuration and Parameters – “i/o” m arameTer eTails enu of arameTers ConTinued i/o “d ” p igiTal uTpuTs arameTers P11.0 – Digital Output 1 N/C(12): Select Function Hold. Reg. Type: Description: Read/Write Allows the Digital Output to be mapped to different functions. •...
  • Page 78 Chapter 3: Configuration and Parameters – “i/o” m arameTer eTails enu of arameTers ConTinued P11.4 – Digital Output 3 N/O(34): Select Function Hold. Reg. Type: Description: Read/Write Allows the Digital output to be mapped to different functions. • The output will change in proportion with the selected function. •...
  • Page 79 Chapter 3: Configuration and Parameters – “i/o” m arameTer eTails enu of arameTers ConTinued igiTal uTpuT unCTion eTTings The following settings are for the “Digital Output x (x): Select Function” I/O parameters. settings for the “Digital Output x (x): Select Function” I/O parameters 11584–11587 Modbus Settings: Description:...
  • Page 80 Chapter 3: Configuration and Parameters – “i/o” m arameTer eTails enu of arameTers ConTinued i/o “a ” p nalog npuT arameTers P12.0 – Analog Input Type Hold. Reg. Type: Description: Read/Write Defines the function of the Analog Input (AI). Range: Modbus Decimal Value: Default (decimal): •...
  • Page 81 Chapter 3: Configuration and Parameters – “i/o” m arameTer eTails enu of arameTers ConTinued P12.2 – Analog Input: Scaling Level Type: Description: Read/Write Allows the selected function to be scaled. The selected function will change in proportion with the input. •...
  • Page 82 Chapter 3: Configuration and Parameters – “i/o” m arameTer eTails enu of arameTers ConTinued P13.2 – Analog Output: Scaling Level Type: Description: Read/Write Allows the selected function to be scaled. The output will change in proportion with the selected function. •...

  • Page 83: Monitor" Menu Of Parameters

    Chapter 3: Configuration and Parameters arameTer eTails ConTinued “m ” m oniTor enu of arameTers P15.0 – Line Frequency Type: Description: Read Only The frequency of the 3-phase supply. Range: Modbus Decimal Value: Default: 45Hz – 65Hz linear scale (1 = 0.001 Hz) Freq(Hz) = (Value / 1000) Modbus Address: Modbus Format:...
  • Page 84 Chapter 3: Configuration and Parameters – “m ” m arameTer eTails oniTor enu of arameTers ConTinued P15.4 – I3 Type: Description: Read Only The RMS current on phase L3. Range: Modbus Decimal Value: Default: 0A – 10,000A linear scale (1 = 1mA) Current (A) = (Value / 1000) Modbus Address: Modbus Format:...
  • Page 85 Chapter 3: Configuration and Parameters – “m ” m arameTer eTails oniTor enu of arameTers ConTinued P15.8 – True Power P Type: Description: Read Only Total True Power. This is a sum of the 3 phases. Range: Modbus Decimal Value: Default: 0kW –...
  • Page 86 Chapter 3: Configuration and Parameters – “m ” m arameTer eTails oniTor enu of arameTers ConTinued P15.12 – Delay Angle Type: Description: Read Only Internal firing delay angle. Displayed for diagnostic purposes. Range: Modbus Decimal Value: Default: 0° – 55° linear scale 0°...
  • Page 87 Chapter 3: Configuration and Parameters – “m ” m arameTer eTails oniTor enu of arameTers ConTinued P15.16 – Ref PF Degrees Type: Description: Read Only The Reference Power Factor used by the iERS saving function. This is the target Power Factor for the iERS saving function.
  • Page 88 Chapter 3: Configuration and Parameters – “m ” m arameTer eTails oniTor enu of arameTers ConTinued P15.18 – HeatSink Temp Type: Description: Read Only The temperature of the internal SR55 heatsink. • The SR55 will trip when the heatsink temperature exceeds 80°C. •...

  • Page 89: Log" Menu Of Parameters

    Chapter 3: Configuration and Parameters arameTer eTails ConTinued “l ” m enu of arameTers Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. venT imes for TarT urrenT emperaTue verload arameTers The event time shows up on the “Start Current,”...
  • Page 90 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P16.3 – Event Time – Holding Register Type: Last Peak Start Current / Last Temperature / Last Overload -3 Description:...
  • Page 91 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P16.6 – Event Time – Holding Register Type: Last Peak Start Current / Last Temperature / Last Overload -6 Description:...
  • Page 92 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P16.9 – Event Time – Holding Register Type: Last Peak Start Current / Last Temperature / Last Overload -9 Description:...
  • Page 93 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P17.2 – Last Trip -2 Type: Description: Read Only Displays the last Fault trip -2.
  • Page 94 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P17.5 – Last Trip -5 Type: Description: Read Only Displays the last Fault trip -5.
  • Page 95 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P17.8 – Last Trip -8 Type: Description: Read Only Displays the last Fault trip -8.
  • Page 96 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P18.1 – Last Peak Start Current -1 Type: Description: Read Only...
  • Page 97 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P18.5 – Last Peak Start Current -5 Type: Description: Read Only...
  • Page 98 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P18.9 – Last Peak Start Current -9 Type: Description: Read Only...
  • Page 99 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P19.2 – Last Peak Stop Current -2 Type: Description: Read Only...
  • Page 100 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P19.5 – Last Stop Current -5 Type: Description: Read Only...
  • Page 101 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P19.8 – Last Peak Stop Current -8 Type: Description: Read Only...
  • Page 102 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P20.1 – Last Temperature -1 Type: Description: Read Only Displays the heatsink temperature at the end of the last successful start -1.
  • Page 103 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P20.4 – Last Temperature -4 Type: Description: Read Only Displays the heatsink temperature at the end of the last successful start -4.
  • Page 104 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P20.7 – Last Temperature -7 Type: Description: Read Only Displays the heatsink temperature at the end of the last successful start -7.
  • Page 105 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. “o ” p verload arameTers P21.0 – Last overload Type: Description: Read Only...
  • Page 106 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. P21.5 – Last overload -5 Type: Description: Read Only Displays the overload level at the end of the last successful start -5.
  • Page 107 Chapter 3: Configuration and Parameters – “l ” m arameTer eTails enu of arameTers ConTinued Each SR55 is tested at the factory, and each unit may have a brief log history from this testing. “T ” p oTals arameTer P22.0 – Number of Starts Type: Description: Read Only...

  • Page 108: Device" Menu Of Parameters

    Chapter 3: Configuration and Parameters arameTer eTails ConTinued “d ” m eviCe enu of arameTers P25.0 – Update Firmware Type: Description: Read/Write Used to upgrade to the latest version of firmware using a USB flash drive Range: Modbus Decimal Value: Default: Modbus Address: Modbus Format:...
  • Page 109 Chapter 3: Configuration and Parameters – “d ” m arameTer eTails eviCe enu of arameTers ConTinued P25.3 – Language Hold. Reg. Type: Description: Read/Write Selects the display language for the touchscreen. Enter the required language from the displayed list. Range: Modbus Decimal Value: Default (decimal): •...
  • Page 110 Chapter 3: Configuration and Parameters – “d ” m arameTer eTails eviCe enu of arameTers ConTinued “n ” p eviCe eTWorks arameTers P26.0 – Address Type: Description: Read/Write Sets the Modbus station number. Range: Modbus Decimal Value: Default: 1 – 32 linear scale ( 1 = 1 ) Modbus Address: Modbus Format:...
  • Page 111 Chapter 3: Configuration and Parameters – “d ” m arameTer eTails eviCe enu of arameTers ConTinued P26.4 – Anybus / ModbusTCP / EtherNetIP Type: Description: Read Only Modbus TCP Communication Module. Active only with Anybus / ModbusTCP / EtherNetIP Communication Module installed. Range: Modbus Decimal Value: Default:...
  • Page 112 Chapter 3: Configuration and Parameters – “d ” m arameTer eTails eviCe enu of arameTers ConTinued eviCe arameTers P27.0 – Reset Defaults Hold. Reg. Type: Description: Read/Write Restores the SR55 to the factory defaults. • Reset to factory defaults does not reset configurations that were set up in the Anybus modules, because the configuration is stored in the communication module;...
  • Page 113 Chapter 3: Configuration and Parameters – “d ” m arameTer eTails eviCe enu of arameTers ConTinued P27.4 – Temperature Format Type: Description: Read/Write Selects °C or °F for displayed temperatures. Range: Modbus Decimal Value: Default: • °C • 0 • °C •...

  • Page 114: Trip Code Descriptions

    Chapter 3: Configuration and Parameters escRIpTIoNs Trip Codes (from Trip Log) Number & Name Description Phase L1 missing at the instant of start up� • The L1 phase is either missing or at a very low level� Input Side Phase •...
  • Page 115 Chapter 3: Configuration and Parameters Trip Codes from Trip Log (continued) Number & Name Description 1201 The motor has been held in current limit longer than the “Start Current Limit Time�” Current Limit • It is likely that the current limit level has been set too low for the application� Timeout Trip •...

  • Page 116: Fail Safe Codes

    Chapter 3: Configuration and Parameters odes (2402 – 2436) oard A trip number in the range of 2402 to 2436 indicates that a process on the main board has been affected in some way and is unable to recover automatically. •...

  • Page 117: Logging Trip (2601 - 2603)

    Chapter 3: Configuration and Parameters (2601 – 2603) ogging Trip numbers that are in the range of 2601 to 2603 indicate that a process associated with the logging has been affected in some way and has been unable to recover automatically. •...

  • Page 118: Saving And Loading An Sr55 Configuration File

    Chapter 3: Configuration and Parameters sR55 c AVING ANd oAdING AN oNfIGuRATIoN Operating parameters of the unit can be copied onto a USB flash drive. To do this, attach the USB flash drive into the USB port under the front cover just above the touchscreen. ADC part number USB-FLASH is a 4GB SanDisk USB flash drive that has been verified to work with the SR55.
  • Page 119 haPter haPter haPter ers ( rinciPles of i intelligent nergy ecovery ystem able of onTenTs Chapter 4: Principles of iERS (intelligent Energy Recovery System) � � � � � � � � � � � � � � � 4–1 Principles of the iERS �...

  • Page 120: Chapter 4: Principles Of Iers (Intelligent Energy Recovery System)

    Chapter 4: Principles of iERS (intelligent Energy Recovery System) RINcIples of The I ers) nabling nTelligenT nergy eCovery ysTem iERS can produce energy savings in suitable applications. However, the user should have an understanding of the application and load characteristics before enabling the feature. Loads which exhibit frequent changes in motor torque may cause the SR55 soft starter to switch rapidly between the iERS ‘on’...

  • Page 121: Principles Of Iers

    Chapter 4: Principles of iERS (intelligent Energy Recovery System) rinCiples of i Every wound-field electric motor must consume some minimum amount of energy to provide a magnetic field which enables it to work at all. With DC motors the field is under separate control, so that the amount of magnetizing energy can be adjusted to be sufficient to overcome losses and provide an armature reaction appropriate to the load.

  • Page 122: Advantages Of Iers

    Chapter 4: Principles of iERS (intelligent Energy Recovery System) dvanTages of i A soft starter with an iERS energy-optimizing feature alters the motor operation. The iERS function reduces the terminal voltage applied to the motor so that the energy needed to supply the field is more closely proportioned to the torque demand.

  • Page 123: How Much Energy

    Chapter 4: Principles of iERS (intelligent Energy Recovery System) nergy The amount of energy used by a squirrel-cage induction motor operating with a soft starter in energy-optimizing (iERS) mode is shown in the following figure (Figure 4.5.1), for the same duty cycle as Figure 4.1.2.

  • Page 124: Estimating Energy Savings

    Chapter 4: Principles of iERS (intelligent Energy Recovery System) sTimaTing nergy avings Basis for estimations: • 3-phase squirrel cage induction motor, standard type� • Supply: 380 to 440V, 50Hz� • Supply voltage > minimum working voltage on motor rating plate� •...

  • Page 125: Iers With The Sr55 System

    Chapter 4: Principles of iERS (intelligent Energy Recovery System) sr55 s WiTh The ysTem During start-up, the SR55 software uses a patented method to compute and store a reference value for the power factor. When the motor has reached full speed and is driving the load at the demanded torque, the SR55 enters the ‘motor running’...

  • Page 126: Chapter 4 Glossary Of Terms

    Chapter 4: Principles of iERS (intelligent Energy Recovery System) hApTeR lossARy of eRms Bre akaway Torque: The minimum torque required to achieve rotor movement for the motor with its load. Cur rent Limit: The current at which the ramp is held. For the SR55, current limit is only active during start-up where it contributes to the motor control function.

  • Page 127: Chapter 5: Communications

    hapter hapter hapter 5: C hapter ommuniCations able of onTenTs Chapter 5: Communications                                     5–1 SR55 Communications Overview                                 5–2 Modbus Serial Communications Overview                                5–2 Modbus TCP Network Communications Overview                            5–2...

  • Page 128: Sr55 Communications Overview

    Chapter 5: Communications sR55 c ommuNIcATIoNs VeRVIeW odbus erial ommuniCaTions vervieW All SR55 soft starters have a built-in RJ12 serial port that can be used to configure and to control one SR55 from one RS-485 master controller, with no additional communications components required (other than RS-485 cabling).

  • Page 129: Modbus Serial Communications

    Chapter 5: Communications odbus eRIAl ommuNIcATIoNs rTu C odbus ommuniCaTions nTerfaCe All SR55 soft starters support serial Modbus RTU protocol (slave) communications. The serial RS-485 communications are accessible from the built-in RJ12 port, as shown below. 1: GND 2: Reserved* 3: Not connected 4: Not connected 5: TXD0-A-OUT (SG-)

  • Page 130: Modbus Communications Configuration

    Chapter 5: Communications odbus erial ommuniCaTions ConTinued odbus ommuniCaTions onfiguraTion The Modbus communication settings are accessible from the Device menu: • Device >> Networks >> Modbus Network Settings >> Address (1 – 32) • Device >> Networks >> Modbus Network Settings >> Baud (9600 – 115200) •...

  • Page 131: Supported Functions

    Chapter 5: Communications odbus erial ommuniCaTions ConTinued upporTed unCTions Modbus RTU specification defines the functions used to access different types of data. • SR55 parameters are defined as holding type registers • For Modbus RTU/TCP Client devices that use Modicon style addressing, place a 4 as the high digit followed by the Modbus address defined in the parameter mapping table Note that SR55 Modbus addressing starts at zero;...

  • Page 132: Memory Map

    Chapter 5: Communications odbus erial ommuniCaTions ConTinued riTe ulTiple egisTers Description: writing register blocks of holding register type (block R/W limited to 8 registers). • Function code: 16 Modbus Function 16 Transaction Table Query Response Field Hex Byte Field Hex Byte Slave address Slave address Function...

  • Page 133: Communication Module Overview

    Chapter 5: Communications – e eTWoRk ommuNIcATIoNs TheR odbus ommuniCaTion odule vervieW Two communication modules are available which allow network communication and control for the SR55 soft starter. EtherNet/IP network communication. • SR55-CM-ENETIP for Modbus network communication. • SR55-CM-MODTCP for Both modules have two RJ45 ports for daisy chaining to multiple starters.

  • Page 134: Modbus Tcp Network Communications

    Chapter 5: Communications – e TCp ( eTWork ommuniCaTions Ther odbus ConTinued ommuniCaTion odule ronT anel ndiCaTor ighTs ronT anel ndiCaTors Location of Front Panel Indicators Network Interface LED Item Front Panel Diagram LED State Description 1 Network Status LED 2 Module Status LED No link, no activity 3 Network Interface, Port 1...

  • Page 135: Ethernet/Ip Network Communications

    Chapter 5: Communications /Ip N TheR eTWoRk ommuNIcATIoNs The SR55-CM-ENETIP EtherNet/IP communication module offers the following functionality: • CIP Parameter Object Support • Implicit and Explicit messaging • Dual switched RJ45 communication ports • 10/100 Mbps full duplex • 2 Input Words from the network master to the SR55 •...

  • Page 136: Using The Ip Configuration Tool (Ipconfig)

    Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued ip C sing The onfiguraTion Config The IP address of the SR55 is set using the Anybus IPconfig utility available from: http://support.automationdirect.com/downloads.html. This section explains how to install the IPconfig utility and how to set the SR55’s IP address. Unzip the file to a temporary folder and run the executable.
  • Page 137 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued Use a switch or crossover cable to connect the starter to the SR55. Start the Ipconfig software. Press the Scan button to have the PC scan for an SR55. The IPconfig utility will automatically find the SR55 units on the network. If the SR55 is not found, click on the Settings button, then choose “Broadcast from a specific Network Interface Controller.”...
  • Page 138 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued Once the settings have been entered, click on the “Set” button and the Anybus module is now configured and ready to be used. It is not recommended to use DHCP, as the address could be changed.
  • Page 139 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued • If the PC is set to a different IPv4 network than the SR55, ie, both PC and SR55 are not set to the same first two octets (1011xxxxxx in this example), the following error will be returned: •...
  • Page 140 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued sr55-Cm-eneT m i/o (i onneCTing To The odule Through mpliCiT essaging The connection parameters for Connection 6 (Extended Control) are as follows: • T->O (Input Data) Connection Point Assembly Instance value is 71 •...
  • Page 141 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued uTpuT eTup ® Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019 Page 5–15...
  • Page 142 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued onfig eTup onfig ® Page 5–16 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 143 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued sr55-Cm-eneT m onneCTing To The odule Through xpliCiT essage There are a few different objects that can be read or be written to via Explicit Messaging: Objects Supported By Explicit Messaging Description Read Only? Service...
  • Page 144 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued Cpu) xpliCiT essage nsTruCTion xamples from roduCTiviTy eries Cpu) xample insTruCTion for seTTing The sTarTer To eTWork onTrol roduCTiviTy ® Page 5–18 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 145 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued Cpu) xample insTruCTion for ConTrolling The TarT and Top of The oTor roduCTiviTy VAlue of To sTART ANd To sTop ® Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019 Page 5–19...
  • Page 146 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued Cpu) xample insTruCTion for reading baCk The aulT sTaTus of The TarTer roduCTiviTy ® Page 5–20 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 147 Chapter 5: Communications /ip n Ther eTWork ommuniCaTions ConTinued Cpu) xample insTruCTion To reseT any faulTs on The TarTer roduCTiviTy Drive State Byte Value State Description Startup Ready & Stopped Running Stopping Fault Stop Faulted ® Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019 Page 5–21...
  • Page 148 Chapter 5: Communications BLANK PAGE ® Page 5–22 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...

  • Page 149: Chapter 6: Accessories

    hapter hapter hapter 6: a hapter CCessories able of onTenTs Chapter 6: Accessories                                        6–1 Optional Accessories                                        6–2 Finger Guards                                                6–2 Remote Touchscreen                                            6–3...

  • Page 150: Optional Accessories

    100 Mbps full duplex, TCP/IP socket interface, capable of supporting 4 simultaneous (master) connections -017 Finger guards, optional, for size 1 Stellar SR55 series soft starter power terminals SR55-FG-1 thru Provides IP20 protection rating Package of 2...

  • Page 151: Remote Touchscreen

    Chapter 6: Accessories emoTe ouChsCreen sr55-kpd-rem 0.90 [23.5] 4x Mounting Holes No.6 self tapping screws Ø1.69 or M3.5 Machine screws [Ø43.0] Diameter hole Neoprene Gasket cut in panel RJ45 Socket (for connecting to starter) Reset Switch USB Socket 2.50 (for firmware [63.0] updates only) 3.70...
  • Page 152 Chapter 6: Accessories How to connect the remote touchscreen • Ensure starter’s Modbus Network Settings are: Even parity and 19200 baud rate If connecting to multiple starters, set the Address to a unique number for each SR55 starter • If remote touchscreen start/stop control is desired, set the Control Method to Modbus Control If the remote touchscreen will only be used for monitoring or configuration (digital input or local touchscreen start/stop control will be used), select the appropriate setting (Local Touchscreen, User Programmable, 2-wire control, or 3-wire control)...

  • Page 153: Rj45 To Rj12 Adapter

    Chapter 6: Accessories rJ45 rJ12 a dapTer sr55-rJ45-rJ12 SR55-RJ45-RJ12 Splitter End Starter End RJ45 Socket RJ12 Plug This adapter allows connection of the Remote Touchscreen, Modbus Splitter, or other Modbus master to the SR55 soft starter. The adapter plugs directly into the RJ12 port on top of the SR55, and provides a receptacle for a communication cable with an RJ45 connector.
  • Page 154 Chapter 6: Accessories – o erial odbus ommuniCaTion pliTTer pTional CCessories ConTinued The Modus splitter allows for multiple SR55 soft starters to be connected to a Modbus RTU network over RS-485. The splitter allows for the interconnections to be made with standard RJ45 Ethernet patch cables from splitter to splitter.

  • Page 155: Communication Modules

    Chapter 6: Accessories ommuniCaTion odules sr55-Cm-eneTip sr55-Cm-modTCp EtherNet/IP Communication Module Modbus TCP Communication Module /ip C Ther ommuniCaTion odule The EtherNet/IP interface is intended to be installed in the SR55 option slot, and allows the SR55 to be connected to an EtherNet/IP network. The interface offers the following functionality: •...
  • Page 156 Chapter 6: Accessories ommuniCaTion odule nsTallaTion nsTruCTions The following installation instructions apply to both network communication modules: • EtherNet/IP Communication Module SR55-CM-ENETIP • Modbus TCP Communication Module SR55-CM-MODTCP sr55 hese opTion modules are specifically designed To be used wiTh The range of sofT sTarT producTs...
  • Page 157 Chapter 6: Accessories – o ommuniCaTion odule nsTallaTion nsTruCTions pTional CCessories ConTinued 5) After the module has been pushed in, the module may feel like it has been seated but may not have. Fig 5a shows a module that may appear to be seated but is not, notice the slight gap between the module flange and the SR55 chassis.

  • Page 158: Replacement/Spare Parts

    -477 SR55-KPD Touchscreen, replacement, for Stellar SR55 series soft starters * These items are exact replacements for the comparable part that is originally installed on the applicable SR55. The power for the fans is internally sourced from the applicable SR55 soft starter.
  • Page 159 Chapter 6: Accessories ooling eplaCemenT eThod eleCTion loWCharT Use the flowchart below in order to determine which fan replacement method and instructions to use. Note for SR55-156 and SR55-180 Soft Starters Cooling Fan Replacement For SR55-156 and SR55-180 soft starters, the fans and internal fan supply voltage could be either 12VDC or 24VDC, depending upon when the soft starter was manufactured.
  • Page 160 Chapter 6: Accessories #1 i ooling eplaCemenT eThod nsTruCTions This fan replacement method is applicable for all SR55 soft starters other than certain SR55-156 and SR55-180 models originally equipped with 24VDC fans, and SR55-414 and SR55-477 models. NOTE: Refer to the Cooling Fan Replacement Method Selection Flowchart on page 6–11 determine which replacement method and instructions to use for your soft starter.
  • Page 161 Chapter 6: Accessories #2 i ooling eplaCemenT eThod nsTruCTions This fan replacement method is applicable only for certain SR55-156 and SR55-180 models originally equipped with 24VDC fans. These particular soft starters with original equipment 24VDC fans will require two SR55-FAN-6 fan kits, and both fans will need to be replaced. The replacement fan kit (SR55-FAN-6) includes a 12VDC fan and a resistor for use in the 24VDC soft starters as described below.
  • Page 162 Chapter 6: Accessories (fan replacement method #2 instructions continued from previous page) 6) Select the Black wires as shown below and place into connector Replacement fan Push shut with pliers 7) Select the Red wires as shown below and place into connector Push shut with pliers 8) Place and crimp the two remining wires (1 Red wire and 1 Black wire) into the final...
  • Page 163 Chapter 6: Accessories #3 i ooling eplaCemenT eThod nsTruCTions This fan replacement method is applicable only for SR55-414 and SR55-477 models. Instructions for Fan Replacement Method #3 Only for SR55-FAN-8; SR55-414 & SR55-477 Soft Starters 1) Remove 4 screws from 2) Slide lower end molding lower end molding.

  • Page 164: Replacement Touchscreen

    Chapter 6: Accessories eplaCemenT pare arTs ConTinued eplaCemenT ouChsCreen These touchscreens are exact replacements for the touchscreens that are originally installed on the SR55 soft starters. ouChsCreen eplaCemenT nsTallaTion nsTruCTions 1) Carefully remove the outer bevel casing around the LCD display. 2) Remove the two plastic rivets below the LCD display.
  • Page 165 Chapter 6: Accessories eplaCemenT pare arTs ConTinued ouChsCreen eplaCemenT nsTallaTion nsTruCTions ConTinued 5) On the reverse side of the PCB, remove the FFC cable from the socket (lift gray part from front edge; do not force.) 6) Place the replacement screen FFC cable in socket, making sure that it is correctly seated.
  • Page 166 Chapter 6: Accessories BLANK PAGE ® Page 6–18 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 167 ppendix ppendix ppendix pdating irmware able of onTenTs Appendix A: Updating Firmware � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � A–1 Updating SR55 Firmware �...

  • Page 168: Appendix A: Updating Firmware

    Appendix A: Updating Firmware sR55 f pdATING IRmWARe Firmware updates are normally not necessary for the SR55 family of soft starters. If, after talking with AutomationDirect Technical Support, it is determined that your SR55 requires a firmware update, please follow the procedure outlined below. It is advised to save your configuration profile to a USB before updating firmware (Home →...
  • Page 169 Appendix A: Updating Firmware 5) Double click on the new directory and inside you will see all of the boot-loading files. Select all of these files and copy them onto the route directory of the USB flash drive. xTraCTed older on usb f lash rive...
  • Page 170 Appendix A: Updating Firmware 6) If it is the first power-up, the SR55 will display the “Automatic Set Up” screen. This screen can be skipped when you plan to carry out a firmware update. To do this, select “Advanced,” then press back, and the status screen will be displayed.
  • Page 171 Appendix A: Updating Firmware 9) Once “Update Firmware” and “Confirmation to Update firmware” has been selected, a loading bar will appear which shows the update process has begun. 10) Wait for approximately one minute for the updating firmware screen to be displayed. This screen shows the progress of the firmware being installed on the SR55.
  • Page 172 Appendix A: Updating Firmware BLANK PAGE ® Page A–6 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...

  • Page 173: Appendix B: Soft Starter Application Considerations � � � � � � � � � � � � � � � � � � � � � � �

    ppendix ppendix ppendix B: S ppendix tArter pplicAtion onSiderAtionS able of onTenTs Appendix B: Soft Starter Application Considerations � � � � � � � � � � � � � � � � � � � � � � � B–1 B�1 –...
  • Page 174 Appendix B: Soft Starter Application Considerations b.1 – m oToR uITAbIlITy ANd ssocIATed oNsIdeRATIoNs The SR55 Soft Starter is based on a series of microprocessor-based optimizing soft starters which have been used world-wide in more than 100,000 critical and non-critical systems. Since 1983, these soft starters have successfully operated with almost every type of load and environment from the Antarctic to the jungle.
  • Page 175 Appendix B: Soft Starter Application Considerations b.1.4 – m aximum oTor able engTh The length of the cable between the output terminals of the starter and the motor should not normally be greater than 100 meters [328 ft]. b.1.5 – p oWer aCTor orreCTion...
  • Page 176 Appendix B: Soft Starter Application Considerations b.1.11 – e ffiCienCy Although the use of the soft starter introduces a power loss, the system still retains an overall efficiency of approximately 99.5%. If the iERS function is selected, then the gain in motor efficiency at partial loads is far greater than the loss of efficiency arising from thyristor heat losses.
  • Page 177 Appendix B: Soft Starter Application Considerations b.2 – R ules foR pecIfIc pplIcATIoNs b.2.1 – i elTa peraTion The SR55 control system allows the soft starter to be installed “in the delta” connections of the motor, which can permit the use of a lower current rated unit. However, in this mode of operation it is important that the soft starter is connected in accordance with the relevant wiring diagram.
  • Page 178 Appendix B: Soft Starter Application Considerations b.2.7 – s Topping Soft stopping can reduce positive surge pressures in pipelines on shutdown. It is necessary to make sure that the ramp-down time is long enough to remove the energy from the fluid before the firing of the thyristors is stopped.
  • Page 179 Appendix B: Soft Starter Application Considerations b.2.13 – a ppliCaTion able ConTinued Table B.2.13 – Applications Breakaway Application Torque Remarks (%FLT) Agitator – Air compressor- rotary, unloaded start 25–35 – Air compressor- reciprocating, unloaded 50–100 – start Air compressor- screw type, unloaded start Usually two-pole motor Ball mill 30–50...
  • Page 180 Appendix B: Soft Starter Application Considerations b.3 – c oNcepTs ANd RINcIples of Ixed peed NducTIoN oToR TARTING ANd oNTRol Since its invention one hundred years ago, the standard three-phase induction motor has become one of the most familiar items of industrial equipment ever known. Due to its simplicity of construction, low cost, reliability, and relatively high efficiency, it is likely to remain the prime source of mechanical energy for the foreseeable future.
  • Page 181 Appendix B: Soft Starter Application Considerations b.3.2 – T nduCTion oTor ConTinued b.3.2.1: T – i igure orque peed urve nduCTion oTor Pull Out Torque ( M TORQUE Locked Rotor Torque ( LRT, M Pull-up Torque Full Load Torque ( FLT, M Synchronous speed SPEED Torque/Speed Curve –...
  • Page 182 Appendix B: Soft Starter Application Considerations b.3.2 – T nduCTion oTor ConTinued Obviously, the larger the difference between the developed torque and the absorbed torque, the faster the acceleration and the quicker full speed is reached, and the greater the stresses experienced by the supply and drive systems during the acceleration process.
  • Page 183 Appendix B: Soft Starter Application Considerations b.3.4 – e leCTro eChaniCal eThods TarTing a: d eThod ireCT The most simple means of controlling energy flow to an induction motor is to interrupt the power supply by a single contactor. Very widely applied, the method is known variously as “direct-on-line”, “across-the-line”, “direct”, etc., and is the usual form of control where low cost is the first and most important consideration.
  • Page 184 Appendix B: Soft Starter Application Considerations b: W eThod elTa and oTher eduCed olTage TarTing ysTems ConTinued There are methods of control, for example, the Wauchope starter, which eliminate or reduce the reconnection transients. However, such starters are expensive and have reliability implications, and they are not widely applied for these reasons.
  • Page 185 Appendix B: Soft Starter Application Considerations b.3.6 – r unning nduCTion oTors Once a start has been completed, the motor operating efficiency becomes of interest. When working at or near full load, the typical three-phase induction motor is relatively efficient, and readily achieves efficiencies of 85% to 95%.
  • Page 186 Appendix B: Soft Starter Application Considerations b.3.6 – r unning nduCTion oTors ConTinued All SR55 Soft Starters are microprocessor controlled, and this gives them a number of advantages. Firstly, there are no adjustments to be made for the energy saving function; all calculations necessary to find the best degree of phase-back of the thyristors for any load condition is made by the microprocessor.
  • Page 187 Appendix B: Soft Starter Application Considerations ppeNdIx lossARy of eRms Bre akaway Torque: The minimum torque required to achieve rotor movement for the motor with its load. Cur rent Limit: The current at which the ramp is held. For the SR55, current limit is only active during start-up where it contributes to the motor control function.
  • Page 188 Appendix B: Soft Starter Application Considerations BLANK PAGE ® Page B–16 Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 189 ppEndix ppEndix ppEndix lEctromagnEtic ompatibility able of onTenTs Appendix C: Electromagnetic Compatibility � � � � � � � � � � � � � � � � � � � � � � � � � � � � C–1 C�0 –...

  • Page 190: Appendix C: Electromagnetic Compatibility

    Appendix C: Electromagnetic Compatibility c.0 – e (emc) lecTRomAGNeTIc ompATIbIlITy As supplied, all SR55 Soft Starters meet the standards of emission and immunity levels defined in the IEC 60947-4-2 and EN 60947-4-2 product standards for AC Semiconductor Motor Controllers and Starters. However, the EMC performance of the controller can be significantly affected by the manner in which it is incorporated into the system in which it is intended to operate.

  • Page 191: C�6 - Purchasing Implications Of Meeting An Emc Standard

    Appendix C: Electromagnetic Compatibility c.5 – emc b AsIc RITeRIA The electromagnetic compatibility of a product is defined by two criteria: 1) Immunity to electromagnetic disturbances generated externally to the product. 2) The type and amount of conducted and radiated electromagnetic emissions emanating from the product.

  • Page 192: C�7�4 - Emissions - Radio Frequency (Rf

    Appendix C: Electromagnetic Compatibility c.7 – b emc c AsIc oNsIdeRATIoNs C.7.1 – i mmuniTy The product standard for immunity requirements is EN 60947-4-2:2012. All SR55 Soft Starter products meet, or exceed the industrial level immunity requirements laid down in this standard.

  • Page 193: C�7�5 - Emissions - Conducted

    Appendix C: Electromagnetic Compatibility C.7.5 – e missions onduCTed Conducted emissions are able to travel great distances and may cause interference to any neighboring consumers connected to the common low-voltage supply network. Allowable levels for conducted emissions generated by semiconductor motor controllers and starters are influenced by the nature of the low-voltage power distribution network.
  • Page 194 Appendix C: Electromagnetic Compatibility C.7.7 – s emC C TraTegies for TTaining and ainTaining omplianCe Where possible, minimize the effect of electrical interference by using the strategies listed below. • Locate the SR55 Soft Starter unit as close as reasonably possible to the motor terminal box in order to minimize cable length�...
  • Page 195 ppenDix ppenDix ppenDix SR55 S izing an taRteR able of onTenTs Appendix D: Sizing an SR55 Soft Starter                               D–1 SR55 Soft Starter Selection Steps                                 D–2 SR55 Soft Starter Overload Trip                                  D–3 SR55 Index Ratings                                         D–3...
  • Page 196 Appendix D: Sizing an SR55 Soft Starter sR55 s TARTeR elecTIoN Teps 1) Determine the required trip class based on the motor load and required start time. See O/L Trip Classes table below. (Also refer to the definitions of Class 10, 20, and 30 Trip Curves in the “SR55 Soft Starter Overload Trip”...
  • Page 197 Appendix D: Sizing an SR55 Soft Starter sR55 s TARTeR VeRloAd The SR55 soft starter provides motor Motor overload 'cold' trip curves (20°C ambient) overload protection, which can be configured through the touchscreen. Overload trip settings are determined by the Motor Current setting and the Trip Class setting.
  • Page 198 Appendix D: Sizing an SR55 Soft Starter TANdARd VeRloAd uRReNT RofIle ANd ycle The SR55 has been designed for a specific Overload Current Profile and Duty Cycle as shown in the previous SR55 Index Ratings section of this chapter. The Overload Current Profile is expressed by two symbols, X and Tx. X denotes the overload current as a multiple of I and represents the maximum value of operating current due to starting, operating, or maneuvering under overload conditions.
  • Page 199 Appendix D: Sizing an SR55 Soft Starter – d NcReAsed TARTs peR eRATING If more than the standard number of starts/hour is required, the SR55 must be derated. To derate for more starts/hour, the motor full load current must be less than the SR55 current. The relationship between the SR55 deration and the starts/hour is given below in Figure 2 and the two examples that follow.
  • Page 200 Appendix D: Sizing an SR55 Soft Starter eraTing xamples Example 1: SR55 Selection and Configuration Step SR55 Selection Application Loaded Conveyor Trip Class Duty In-Line or In-Delta In-Line Ambient Temperature 40°C Altitude 1000m Full Motor Load Current Current Limit 4 x 80A = 320A Number of Starts/Hour Deration Factor (from Fig2) 083...
  • Page 201 BLANK PAGE ® Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...
  • Page 202 ® Stellar SR55 Series Soft Starter User Manual – 1st Ed, Rev F – 09/18/2019...

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